Biochemical process and apparatus for manufacturing food products



March 4 s. A. JEFFREYS BIOCHEMICAL PROCESS AND APPARATUS FORMANUFACTURING FOOD PRODUCTS File d Aug. 21, 1940 mvENroR GEORGE A.JEFFREYS ATTORNEY Pa'tcnted. Mar. 6, l9 45 Biochemical. rnocEss' ANDAPPARATUS I FOB. murao'runme roon PnonUc'rs George A. Jeffrey's,'Calcium, N. Y., assignor, by direct and mesne assisnments, to NelsonLittell, New Canaan, Gonni Application August 21, mesa-a1 uorssam 21Claims. (.01. 99 9 This invention-relates to new andimiar ovedbiochemical processes and'apparatus foruse in the manufacture of specialfood products from inexpensive raw materials, and particularly toimprovements in or relating to 'the manner-of practicing the inventiondisclosed and claimed in my United States Letters Patent No. 2,095,638.

The inventionof said Letters Patent has prow, vided a new type of liquidbase material for food products. and new co mposlte food products madetherewithLin which special physical. properties 'andbeneficial foodconstituents. have been dethe handling and separate treatment of batchesof material in vats. I As aconsequence the procedure is burdensome andunduly expensive, and diiliculty is encountered in maintaining thedesired-uniform control over the conditions and results of thetreatments. The system becomes quite burdensome when it is necessaryfora single plant, to produce several thousand gallons of the liquidbase material per day. Prior to the present invention-however, thetreatments deemed necessary for the practice of the process and theveloped by a succession of treatments of a starting materialcomposed-largeiy'of cereal starch. The liquid base material resultingfrom the treatments is characterized by a syrupy liquid con- I sistencyand by the presence of simple sugars,

qualities of the materials at various stages in the course ofmanufactureprecluded the adoption of any oth r system of a more econo ical or morepra tica nature. For example, gel tinization of I the tarch content ofthe starting material and ,disaccharides,- yeast, vitamin B1, vitamin G,en-

zymes, lactic acid, and lactic acid organisms, all

in comparatively high concentrations. By combining this material withsolid food in-the form of a meal or mash, valuable composite foodprodnets are obtained which possess the beneficial I constituents of theliquid base and in which such constituents may be extended by the actionof the base material. The physical qualities of the liquid base materialrender it advantageous for use as an adhesive binder when formingvarioustypes of solid feeds or meals into kemels, granules, pellets,.oak es orother special shapes by meansof peiletingi or molding machines.

Heretofore the liquid base material has usually been manufacturedsubstantially in accordance .with the "embodiment described in saidLetters Patent No. 2,095,638. A batch of starting mate- I rialcontaining cereal starch, powdered -milk, sugar or molasses and water ismixed in a vat and then boiled until the starch has disrupted and,

become gelatinized. At this stage the-material has a pasty. non-flowingconsistency.. It is then cooled to about C. and afterward is treatedwith diastatic enzymes, inoculated with yeast rich in vitamin B1 andallowed to .ferinentfor about 8 to 12 hours. These steps convert sucroseinto invert sugar'andhydrolyze the gelatinized starch. They alsoincrease the yeast and vitamin contents of the'.material. I The batchis, then enriched with molasses-or sugar, then inoculated with lacticacid bacilli and then cultured for 12 -to 16 hours, after whichtreatments the material. changed in physical form from a paste to a,syrupy liquid and has become ready for use as a the subsequent coolingof the gelatinized materia'to a comparatively low temperature have beencarried out as steps separate and distinct from the later conversion ofthe starch bythe action of diastatic enzymes, because the heatingtemperatures and the period of heating required for the gelatinizationhave been such that the diastatic enzymes, if present at that stage,would be destroyed before acting on the gelatinized starch. I a

. Among the objects of mypresentinvention are to" provide a new-anduseful process and new i apparatustherefor by which the aforesaid food Imaking zetho'd and other biochemical processes using 'st ch as aprincipal raw material can be I carried out with greatereconomyandemciency, than heretofore: with greater speed for a givenoutput of product, thereby increasing the producing capacity of a plantofgiven size: with the production of more concentrated products; and

' eonstituent'or binder of the, new composite food products.

Eachstep'of this previousembodiment involves 'with'more efficient andmore uniform control over process operations, which reduces operatingcosts and otherwise increases the emciency of 1 "manufacture.

Another object of this invention is to-Iprovide improvementsinthe'manufacture of food prod- -ucts or the like fromstarches whichenable the gelatinization of the starch and the conversion I of thegeiatinized starch bythe action of enzymes to be carried out in a'continuousmanner, while I maintaining the materials concentrated yet. ina liquid and iiowable state as distinguished from the usual pasty ornon-flowing state of conecen- I 8 l a trated starch materials afterdisruption or inizati0n .accordin'gto known methods.

, I have found it possible .to produce a concen .trated liquid basegasdescribed. composed laurel! of sugars roduced from starch and containingsub tantial concentrations or vitamin Bi, vitan'fin G, enzymes, yeast.lactic acid and lactic acid organisms, by adapting the process ofmanufacture to special characteristics of the diastatic ,enzymes and ofcertain starches, by carrying out the gelatinization and the conversionof the starch almost simultaneously in the presence of the enzymes andof agents which accelerate starch hydrolysis, and by maintaining specialcontrol over the temperatures and time of heating by'which to eflect thestarch gelatinization and conversion. In the practice of this invention,the starch component of the starting mixture is disrupted andgelatinized and then hydrolyzed and rendered liquid immediately upongelatinization, so that it becomes possible to use a more concentratedstarting mixture thanrheretofore yet to keep the material in liquidform. This almost simultaneous gelatinization, liquefaction andconversion of the starch also allows the treatments to be carried out bymeans ofja new continuous process and new apparatus having importanteconomies and other advantages over prior practice. In addition, itpermits further steps in the production of the desired final product tobe carried out 'in an advantageous manner.

I have found that some starches, when mixed with water and heated, aredisrupted and gelatinized at lower temperatures than others. For

instance, wheat starch disrupts at about 62 C.,'.

corn starch at about 70 0., and potato starch at about 96 C. -When thestarch cells are disrupted, a colloidal dispersion orgelationizationwith water follows, andat this point a concenditions, theenzymes in the presence of the starch-hydrolysis accelerating agentconvert the gelatinized starch into dextrine, maltose and then dextroseimmediately upon gelatinization of the starch, and the mass of materialis kept liquid and prevented from assuming a pasty or non-flowingconsistency.

With the 'use of these features, it becomes possible to carry out themanufacture of food products from starches in a new and advanta-- geousmanner. For example, the manufacture of my special liquid base for foodproducts may be started with a mixture of wheat sta ch, 7 to 9% of maltflour 'made from barley m t (or an equivalent amount of diastaticenzymes from other sources, such as Asp. oryzae) to of powdered milk,and/or 5 to 15% of soy bean meal. By combining this mixture with about 1to 2 times as much'water, by weight, geiatinization; liquefaction andconversion of the starch in the mixture may be accomplished in aboutseven minutes while progressively increasing the temperature of themixture from about 60;to about 80 C. By the time the starch has beenhydrolyzed and the final temperature of about 80 C. or higher has beenreached, the thermal inactivation point of the enzymes is attained andthe enzymes automatically become dormant. or

in some cases destroyed,.although the constituents of the liquefiedmaterial have been found to act as buifers which tend to protect theenzymes against permanent inactivatiomor de struction. The finaltemperature in any event ing similar amino compounds may be used, or,

inorganic nitrogenous compounds such as ammonium. sulfate, ammoniumphosphate and the point of diastatic enzymes varies inversely with thetime ofmexposure of the enzymes to any given temperature; for instance;malt amylase in a plain salt solution is destroyed in one hour at C. andin only a few minutes at U0 C.

In accordance with the present invention, therefore, I take intoconsideration and utilize thequalities'of starches which disrupt" atcomparatively low temperatures, the thermal inactivation qualities ofdiastatic enzymes and the action of starch-hydrolysis accelerationagents such as amino acids contained in milk, soy bean mealand the like,and I begin the operation of my improved process with a startingmaterial composed largely of starch having a low-cell disruptiontemperature in ,admixture with diastatic enzymes and such acceleratingagents. This material is combined with water to form a concentratedmixture, and the resulting mixture is then heated to such temperaturesabove the disruption temperature of the starch and for such a period oftime that most of the starch becomes disrupted, gelatinized andconverted into sugars before substantial inactivation of the diastatlcenzymestakes place. 'Underthese conwith suitable heating means and athird sec conveying and heating apparatus of practical size in which thegelatinization, liquefaction and conversion take place continuously andfrom which is continuously obtained a large output of A a liquidintermediate product composed largely of dextrose. This product may becontinuously enriched, in th same apparatus, with sucrosebearingmaterial such as molasses, and the en riched material may then be cooledcontinuously to reduce its temperature to a desired range before batchesof it are collected in culturing tanks where fermentations with yeastand lactic acid organisms take place. After these fermentations, thematerial has become a liquid base materlal of the character hereinabovedescribed.

The new apparatus provided for the practice of my invention, accordingto a preferred embodiment, includes a mixing bin for holding drystarting ingredients, a supply tank fcr'make-up water, mixing troughmeans for mixing together continuous streams of the starting ingredientsand water andfor heating the resulting mixture,.

and means for feeding the starting ingredients,

and the water at regulated rates into and through the mixing trough. Themixing trough means may include a series of sections, with the firstsection a simple stirring and mixing section, the second section apreheating section equipped ,tion also equipped with heating means so a.to

effect the gelatinization, liquefaction and conversion of the starchingredients. The heating projecting into the trough, and temperature myimproved process, and

v the feeder II, as at 20.

' clients may be introduced into regulator may be provided near the endsof the respective sectionsto govern the heat supply in obtainedtherefrom when thesi is rotated, as well as a slight conveyingactionilengthwise of accordance with the'temperature of the mixture 7and thus prevent the mixture from exceeding the V temperatures desiredfor p oper treatment. The

mixture'issues from this treating system with most of the starchcompletely hydrolyzed and 'bespaced apart a distance of. about 8 to 10inches.

in liquid form. To effect further preparation thereof for the productionof a liquid base as hereinbefore described, the liquefied material fromthe third mixing trough section may. be dis charged into a fourthsection where molasses,

cane r beet sugar, or other sucrose-bearing material is added at aregular rate to enrich the liquid. The enriched liquid may then passcontinuously from this fourth section into a constant-level holdingtank, and from the latter it may be pumped through a cooling coil sothat illustrative embodiment. The following description refers to theillustrations on the accompanying drawing, forming a part hereof, inwhich Figure 1 is a schematic vertical, longitudinal cross section,showing one embodiment ofapparatus which may be used for the practice ofFigures 2 and 3, respectively, are transverse cross-sections along lines2-2 and 3- -3 of Figure 1., Referring to the drawing for details of theillustrated embodiment, a hopper III is provided for holding a mixtureof substantially dry start ing ingredients, the hopper having agitatingof stirring means I! therein and having at its bottom a percentagefeeder l4 in'the form of a screwconveyor or the like. terial fromthehopper into a chute l6 leadinginto the'first or mixing section It, or amixing trough 30. The rate of feed of material from the hopper into themixing section it maybe controlled by regulating: the ra .A water supplytank 22 is provided above the Water may be introduced into tank 22 froma pipe 23. If this water should be too cold for emcient operation of theprocess, it may be tempered bymixture with warm waterfrom' a pipe 25,the proportions of cold and warm water being regulatedby a mixing device21. Warm water introduced through '25 may" be. derived from an overflowpipe "connected with .a. he t 9 18 system I10, I22, hereinafter to; i bedescribed.

changeor c n will be understood that water-from mm :2

I! at a reguiated rate"throughthe chute ll. L The mixing section llisdefln h an elongated trough 80 through which extends a thereon. [Thepaddles {I are s'et on" a shaft flatsuchaplteh The feeder ll delivers mate of rotation of ed by partof,

the trough 30. For example, the paddles 34 may The mixing section I.is'partially separated from a second trough section "by means off'apartition or baflle 4 2, beneath which the must pass in travelling fromI8 into '41)." This baffle prevents floating lumps fromypasslng? 'to thesecond section 40 without having been broken I up by the action 0section l8. v

The paddles 34 in the second section III provide a 'less violent actionthan those in the mixing section [8, and toward the right-hand end of fthe paddles I! in the mixing section 40 they preferably are arranged soas to action.

impart onlya stirring and very slight conveying S In addition to thismixing and conveying means, the second trough section" isprovided withheating means for progressively increasing the temperature of themixture passing therethrough. The heating means, for example,coinprisesa plurality of steam fingers H which open into the lowerportion of the trough and are con-.-

' nected with a' common steam header or supply The steam fingers 44,forexam'ple, may Y pipe 46.

'be arranged about'8to 10 inches apart between padd1es,34.Connected-with the steam supply pipe 46 i519; temperature regulator 48-having a bulb 50 located near the; end-of the trough section 40 inposition to respond to the temperature temperature of the mixture at theend oftrough "section III, so that when the mixture tends to exceed apredetermined temperature the amount of steam introduced through thesteam flng is decreased accordingly.

From the foregoing, .it' will be apparent that the solid ingredients andwater introduced into the mixing section l8 from chute I6 and pipe 24,respectively, are stirred and mixed together in section l8 and pass fromthe latter into sec- .tion Ill-beneath the partition or'baflle 42., In

dles lland pr'ogresslvely heated to a'predeter-- I through the steamfingers ll. In'the preferred embodimentof my invention, thissecend'trough. section III is :employed as a preheating section,

mixing section I! and connected with the latter I by means of a pipe,oontrolledbfia valve II.

section 40, the mixture is agitated by the padmined temperature by theintroduction. of steam and thetemperature regulator I8 is set so as tosion phase of the process. This trough may be,

' maybeintroduced into It at greguhted throuah'pip 24, and. that solidstarting m cause-the mixture'to be heated to a temperature approximatingthedisruption temperature of the starch by the time the mixture has reachedthe end of trough section 40,

As .shown'imFlgure 1, another mixingtrough I, is provided for completingthe starch converfor example, about .25% larger than trough, so as toaccommodate the addition of'molasses to the mixture as hereinafterdescribed.-v Trough l l-is shown as being located below-trough", but itwill be apparenvthat other arrangements, such -as. a continuousstraight-line system, may be employed. A shaft 02,.extendslongitudinally through trough I and iii-equipped with radial 4 1'paddles N which agitate the material in trough shaft 82carryingastirring ornixjin'g. dies 34 the right-hand td the left-handendof trough ers M pletely sterile.

through pipe 8|.

88" as seen in Figure l. The paddles 84 in most of trough 50 may bearranged, for example, about 6 to 10 inches apart. 'As seen inFigure. 1. however, trough 60 is divided into two sections 86 and 88,respectively, by means of a baille or partition I0, and the paddles 64in section 88 are prefer.-

ably arranged more closely togetherso as to provide a greater degree ofagitation in section 88. Section 86, like the preceding section 40, isprovided with a plurality of steam fingers '|2 which extend into thebottom part of the trough from a common steam header or supply pipe 14.A temperature regulator 18, similar to regulator 48, is connected withthe supply pipe 14 and provided with a bulb 80 positionedso as torespond to the temperature of the mixture near the end of trough section66. A gauge 82 indicates the temperature of the mixture atthis point.

Material reaching the end of trough section 48 overflows therefrom intovthe inlet end of trough section 66 through an overflow pipe 84controlled by the valve 86. Most ofthe material from section 40overflows into section 68 through this pipe. Another pipe 88; controlled.by a valve 80, .extends from the bottom of section 40 into the upperpart of section 88 to allow drainage of material from the former and toprevent sedimerit,- such as .cereal particles, from accumulatlngtherein; I

The trough section 66 and the heating means for maintaining a constantlevel of liquid therein. For example, a float I I is located in the tankso as to control a valve H2 in a discharge pipe 4. One end of pipe H4 isconnected with the bottom of tank I00 through a pump IIB. Another end ofpipe II4 enters the jacket I20 of a continuous cooling system throughwhich extends a cooling pipe I232. When the level of liquid in tank I00exceeds a predetermined amount, valve H2 is opened and liquid is pumpedfrom the tank into and through iacket I20. During its passage .turingvats I30 and I32. A pipe 34 leading from jacket I is provided withvalved branches extion of the fermentation in vats I or B2, theresulting product may be discharged through a tending tothe respectiveculturing vats. A thermometer I36 indicates the temperature of'thecooled liquid entering the vats. Upon complepipe I by means of a pumpI42.

therein are utilized to effect the active gelat-' iniz'ation,liquefaction and conversion of starch in the mixture flowing throughthis section after delivery from the preheating section 40. Thetemperature regulator "is set: at a predetermined point so that themixture, when it reaches the location of bulb 80, will have atemperature The following example. illustrates the use of theabove-described process and apparatus for the manufacture of a liquidbase material for food products:

not departing substantially from a predetermined value. The introductionof steam into the mixture lengthwise of section 88 causes a progressivefore the mixture reaches the battle I0. The'flnal temperature attainedat this end of the trough section 80 may be such that the materialenter- 1 gallon (8 pounds) of water to 5 pounds of dry ing the nextstage of the process will be com- A The converted material from section.88 flows beneath baffle I0 into section 88, where it is enriched withsucrose and other'diesirable constituents by the addition of molassesthrough a molasses supply pipe SI. A meter 82 on pipe 8| indicates therate of molasses addition. A valve 84 controls the rate of flow. Ithrough pipe 9| from pipe 88 by means, of a pump 88. It will be evidentthat the paddle arms 84 in trough section 68 effect a thorough mixing ofthe stream of converted material issuing from section 88 with the streamof molasses introduced After the molasses has been combined with theconverted material at 88, the resulting mixture controlledby valve I84;or, the resulting mixture Molasses is forced The dry ingredients andwater entering.

A mixture of solid starting ingredients is provided in hopper I0containing, say, of wheat starch or other starch material having a lowgelatlnizing temperature, 15% of powdered milk, 10% of soy bean meal, 5%of malt flour and 1% ofcommon salt. A supply of water is provided intank 22 at a temperature preferably not less than 13 C. and not higherthan 28 C.

At the outset of operations the troughs 30 and are preferably fllledwith water. The apparatus is then started in operation, and'streams ofthe solid ingredients and water, respectively,

.are introduced at regulated rates into the first trough section I8. Theproportion of water to dry ingredients under average conditions is abohtingredient. This proportion may .be varied according to theconcentrations desired. I

The rate of rotation of shafts 82 and i2 is determined and controlled inrelation to the rate of introducing dry ingredients and water intosection I8, so asto maintain the desired rate of flow of materialthrough the system. For example, shaft 32 may be rotated at a speed ofabout 150 R.-P. M., and shaft 82 may be rotated at a speed of about RP.M.

ouch section I8 are thoroughly mixed together in this section by theaction of the paddles 34 therein. From section I8 the mixture travelsbeneath baiile 42 into section'40, andduring its travel "through sectionon steam is introduced into and mixture of the type indicated above, thetemperaoverflows .into a tank III through a pipe I82,

ture regulator '48 is setto keep the end tempera- I ture in section 48at about 60 to 61 C. I The mixture flows continuously from section 48into trough section 88, and in the latter steam or sediment settledtherefrom may be drained into tank I through a draiupipe IlLcontrolledis introduced at such a rate, controlled by the temperature regulatorI8, that the temperature of by valve l ll. Tank m is equipped with meansf" the mixtureis progressively increasedto a final version thereof.

ingaccomplished their purpose.

' culture as in the first in'stance.l A To stimulate the development oryeast to'the .iullestextent aeration'should be instituted aboutsequently maintained in trough section Stan increasing temperature.gradient covering the range oftemperatures from about 60C.,to about 82C. Disruption of the starch component of the -mixture takes place soonafterthe mixture has I been introduced into trough section 66, anddisruption and gelatinization of the starch are foltained the finaltemperature oi 80 to 82 G. or more, and liquefaction and conversion ofmost i aavqoeu point of about 80 to 82C. or more. There is con- 4 7 ofthe starch have been completed. By the time this final temperature isreached sterilization of the liquidis effected and the dias'taticenzymes in the mixture become dormant, but not before havv thefermentation.

The converted material passes from trough section 66 beneathbaffle'lll'and intotrough'section 68, where molasses is addedcontinuously at a rate equivalent to about 10 to 30%, by weight, of theconverted material, preferably about After the molasses has beenincorporated the liquid over-flows into tank I00, where a substantiallyconstant supply thereof is maintained. From tank I00 accumulating liquidis pumped through the cooling coil or jacket I20, and during its passagethrough this coil coolwater is pumped. through pipe. I22 at such atemperature and sucha rate that the cooled liquid will leave the coil,for example, at a temperature ofabout C. I At this-point the liquidshould have a pH of not. more than 1 24Baum. L

The cooled nutrientliquid irom' coil I20 passes itis inoculated with La,stronzculture of seed yeast, preferably equivalentto about 1% of liquidyeastor about of compressed yeast (S. cereoisiae). That is to say, 1000gallons of nutrient liquid takes about 10 pounds oi liquid yeast orabout 5 pounds or compressed yeast. At the time of the yeastinoculation, or a .few hours later, the a same nutrient liquid isinoculated with a 48-hour milk culture or any of the lacticacidorganisms used for iood, such as B. acidophilus, B. bulgarh cus,etc. Onequart ofi'nilk culture per 1000 gal-f lons of nutrient,vsolution is sumcient; The

amounts of yeast and lactic acid organism cul- I ture, of course, can bevaried accordin's t the v type of fermentation-desired, a Afterabout 12hours ot-culturing, portions of the culture in this first vat may beused'to inocu- .late one or more additional vats of the nutrient liquid,using about 20 to 30% of the culture .to .each'vat. After about 12hours, portionscf the A cultures in vats so inoculated may in turn beused to start other vats. This process may be re-v peated as long as theculture appears'vigorous and tree from excess contamination.'Ir'desired, however, each vat may be started with 'apure 2 to 12 hoursaiter'inoculationand should proamount oiair or other gases, as wellasthe peerind of aeration, can be varied to suit. diflerent requirements.If the culture is vigorously and a density oi about 20 to into one ofthe culturing vats "land, I32, where aerated the resulting liquidbase-material will have a higher yeast contentya lower sugar con-j tentand a lower density (about 9 B. or lower). With moderate aeration thedensity willbe about l5or 16 B., and the product will have a highercontent of lactic acidand lactic acid organisms.

I concentrations of lactic acid and lactic-acid organisms. This lattercondition is also desirable when foods made with the liquid basematerial are to be molded or pelleted, the liquid base material in suchcases acting as-an adhesive. on the other hand, it issometimes desirablethat the liquid base material contain a higher content of yeast,especially when it is to be used in foods of a semi-solid nature,andunder such conditions a greater amount of aeration is employed duringThe nutrient liquid in each vat is usually cultured for a total periodof 48 hours or "more to allow lacticacid organisms to develop and "tobuild up a suflicient amount of lactic acid. The lactic acid, togetherwith the sugars remaining, in the product, acts as a carrier and apreservative for the various beneficial constituents developed inthe'course of the process, such as yeast, enzymes, vitamin B, complexvitamin G, lactic acid organisms and other beneficial end prod-,- uctsthat may be developed. --When the cultur ing has been completedafinished liquid basematerial is obtained which is ready to. beincorporated with any desired solid food or meal to pro,-

- v fact that the powder is bonded into granulesby.

the syrupy base materiaL. For pelletinqrormolding,'soi ne meals requiremore of the base material than others; for example, a fine powdery mealmay? require about 3% or the base-mate! rial to produce firm, cohesivepellets, while a bulky feed may require as much as 7 to 9%. In preparingcertain therapeutic products for use in controlling poultry diseases,the meals may be incorporated with as much as 15 to 20% of the liquidbase material. Other valuablereeds of a I semisolid nature can beprepared by using as "After some composite foods pared by the useof thespecial basematerial, it

much as 75% of theli'quid base material with as littleas 25% of meal.When combined with silage, about. 2' to 5% of the base material isusually employed.

have been premay be desirable to remoye part'of any excess .moisture bypassing the food'through low;tem-,

, beneficial peratllre Absolute dryness, however, is. not necessary ordesirable since the sugars in-the presence of moisturetendto'preserve'the iood and to act as; conveyors'i'or enzymes, vitamins,organisms, andcother end products. which areimportant to the qualityoithe food and to-easy'digestion thereof. Furthermore, when the basematerial is incorporated with the ifi oi or other solid food itsbiochemical properties continue to act within such meal or food in thepresence of moisture. For instance, starch may be further converted todigestible sugars, yeast cells and lactic organisms may be increased,and various other beneficial properties may be developed. f Whilenumerous details relating to a specific embodiment of my invention havebeen described hereinabove, it will be understood that my invention isnot restricted to these details of the to various other embodimentsutilizing its novel features. as set forth in. the appended claims.

Some of thenew features of my invention may be employed to advantage notonly for the production of a liquid base material for composite foodproducts, but also for the practice of various starch conversionprocesses in the food and allied industries. I therefore desire that myinvention be accorded a scope fully commensurate with its novelcontribution to the art, as limited only by the fair requirements of theappended claims.

I claim: 1. In a biochemical process in which starch isconverted intosugar, the steps which comprise illustrative embodiment but that itextends also aemons ing at temperatures above said cell-disruption"temperature so that starch is disrupted and converted intodextrose'before said enzymes become inactive. 4

'l. A process as describedin claim 6,'said controlled heating beingcarried out so as to increase the temperature of the mass about 1 to 3degrees centigrade per minute,

x 8, The process for manufacturin a liquid base for food products whichcomprises forming a mixture-with water of solid materialscomposedlargely of starch and containing diastatic enzymes andstarch-hydrolysis accelerating agents, stirring the mixture andgradually heating the same in a predetermined range of temperaturesabove the disruption temperature of said starch for a predetermined timesufficient to disrupt, liquefy and hydrolyze said starch .while saidenzymes remain active', enriching'the liquefied mass with 7 sucrose,then coolinlthe same and thereafter culturing the same with yeast andlacticacid organisms untilsucrose has been inverted and the desiredlactic acid content and physical consistency have been attained.

9. In a process for manufacturing a liquid food material from startingmaterial composed large- 1y of starch, the steps which comprisecontinu-; ously mixing in predetermined proportions a stream of waterand a stream of starting mate- 'rial composed-largely of starch having alow disruption temperature containing diastatic 2. In a biochemicalprocess in which starch in a starting material is disrupted andconverted into sugar, the step which comprises effecting disruption andconversion of the starch in a single course of treatment by heating thesame, in admixture with water and-diastatic enzymes and in the presenceof accelerating amino acids such as contained in powdered skim milk andsoy bean meal, to temperatures above the cell disruption temperature ofthe starch, and controlling the temperatures and time of the heating sothat said enzymes remain active while the starch is being disrupted andconverted.

3. A process for converting starch intosussi' which comprises forming amixture containing water, starch a low cell disruption temenzymes andstarch-hydrolysis accelerating agents, stirring the resulting mixturewhile advancing the samecontinuously through a predetermined path,progressively. increasing the tem-. perature of the mixture in a portionof said path to approximately the disruption temperature of the starch,progressively increasing the temperature of the mixture in a furtherportion of said path to a flnal temperature substantially above saiddisruption temperature, flowing the mixture through said further portionat a predetermined rate suflicient to cause disruption and completehydrolysis ofstarch before-inactivation of said perature, diastaticenzymes and an agentwhich accelerates the hydrolysis of starch, andheating said mixture at temperatures above said cell disruptiontemperature for such a time that the starch is geiatinized and convertedinto dextrose before the thermal inactivation point of said enzymes isattained.

heating of said mixture, after the starch has been converted, at suchtemperatures and for such a time that the mixture is rendered sterile,

5. The process of claim 8, said accelerating a ent comprising aminoacids such as contained in owdered skim milk and soy bean meal.

' 6 In the manufacture of a liquid food material. the steps whichcomprise providing a mixture of solid ingredients composed .largely ofstream of starting-material composed. largely of 4. The process of claim3, and continuing the starch and containing dlastatic enzymes and aminoacids which accelerate. the hydrolysis of starch, combining said mixturewith water in predetermined proportions to form a wet mass of hi hstarch concentration, stirring the mass and gradually heating the samefor such a time and to such temperatures above the cell-disruption tem-'perature of said starchthat the massbecomes sterilized, and controllingthe rate of said heatenzymes, and continuously discharging from saidfurther portion a uid material the dry substance of wh h composedprincipally of sugars. s e

10. In a process or manufacturing a liquid base material for oodproducts from starting material composed largely of starch, the stepswhich comprise continuously mixing in predetermined proportions .a'stream of water and a starch having a low cell-disruption temperatureand containing diastatic enzymes and amino acids which accelerate starchhydrolysis, stirring the mixture while advancing the same continuouslythrough a predetermined path, progressively increasing the temperatureof themixture along said path to a nnaltemperature substan tiaily abovethe cell-disruption temperature of the starch, increasing thetemperature of the mixture from said cell-disruption temperature to saidfinal temperature at apredetermined rate suilicient to cause disruption,liquefaction and hydrolysis of said starch without destroying saidenzymes. and maintaining thermixture near said final temperature lizethe same.

11. In a process for manufacturin a liquid base material for food fromstarting material composed largely of starch, the steps which comprisecontinuously mixing in predetermined proportions a stream ofwater and astream cl for 'a time suflicient tosterithe temperatureof the mixturealong said path to a final temperature substantially above thecell-disruption temperature of the starch, in,--

creasing the temperature of the mixture from said cell-disruptiontemperature to said final, temperature at a predetermined ratesuflicient to cause disruption, liquefaction and hydrolysis of saidstarchwithout destroying said enzymes,

continuously enriching the liquefied" material with sucrose-bearingmaterial, continuously coolingthe enriched material, and'thereafterculturing thejseme with yeast and lactic acid trganismsuntiisucrose has been inverted and the desired, lactic acid contentandphysicalconsistency havebeen attained.

1 1912. In a biochemical process for manufacturing a-llquid basematerial for food products containing substantial concentrations ofvitamin Bifl 'vitaminlG, yeast, enzymes, lactic acid, lactic whichcomprise mixing water with a starting material composed largely of wheatstarch and containing diastatic enzymes, powdered skim milk and ;soybean meal, progressively heating the mixture, while stirring, to a finaltemperature 'well above cll." 0., and heating the mixture grad-- nailsin the range between about 60 C. and said final temperaturev at a ratecausing 'gelatiniz'ation, liquefaction and conversion of said starchbefore inactivation of said enzymes.

13. Ina biochemical process for manuiacturing a liquid base material forfood products containing substantial concentrations of vitamin B1.vitamin G, yeast, enzymes, lactic acid, lactic acid organisms and simplesugars, the steps which comprise mixing from 1 to 2 parts, by

weight, of water with 1 part of a starting materialcomposed largely ofwheat starch and con--' taining small proportions of malt flour,powdered milk and soy bean meal, progressively heating the mixture,while stirring, to a final temperature of at least about 80 0., andeffecting said heating in the'rang' between about 60- C. and

- about 80 Quart arate of about 1 to 3 degrees centigrade increase intemperature per minute thereby causing almost simultaneousgelatinization, liquefaction and conversionoi said starch.

14. A biochemical process for manufacturing a liquid base materialfor-food products containing substantial concentrations or vitamin B1,

- vitamin G, yeast, enzymes, lactic-acid, lactic acid organisms andsimplesugars, which comprises mixing 1mm 1 to 2 parts, by-weight, oiwater with -1 part of 'a. starting material composed largely of wheatstarch and bontaining about 7 to 10% of malt flour, about to 20%-o!powdered milk and about 5 to 15% of soy bean.

meal, progressively heating the mixture, while multaneousgelatinization, liquefaction and con version of said'starch, thereafteradding about to 30%61 'molasses' to the converted material, based on,theweight of the latter, then cooling .the" material to a temperature below35 C., and

thereatter inoculating the cooled materialwith yeast, inoculatingthesame with a milk cultureof lactic acid bacilli, culturing theinoculated material for a. period in excess of 36 hours andaerating thesame during a part of said'period. 15.'A biochemical process formanufacturing a liquid base material for food products containingsubstantial concentrations ofvitamin B1,

vitamin G, yeast, enzymes, lactic acid, lactic acid organisms andsimple-sugars, which com- '10 prises providing a supply of water at atempera ture not exceeding 28 C.,' providing a supply of startingmaterial composed largely of wheat starch and containing about 7 to 10%.of malt flour, about 5 to 20% of powdered milk and about v 5 to 15%"01soy bean meal, continuously com-- bining streams of said water and saidstarting material and mixing the same together in a proportion of about1 to 2 parts, by weight, of water to 1 part of solid m aterial, stirringthe mixtur'e: and advancing the same in a continuous stream through apredetermined path, progressively increasing the temperature of themixture along V said path to a final temperature of at least about 800., effecting said heating in-the range between '25 about 60" -c., andabout 80" c. at a rate or about acid organisms and simple sugars, thesteps 1 to 3 degrees centrigrade increase in temperature :per-minute soas to cause almost simultaneous gelatinization, liquefaction andconversion ofsaidstarch, continuously flowing the so converted materialthrough an enrichment zone .35 C. in said cooling zone,continuouslydischarging cooled material from said cooling zone intovats, and thereafter fermenting batche of the material with yeastandlactic acid bacilli in said vats.' a

16. The method of simultaneously gelaiinizing and hydrolyzing starchwhich comprises forming a mixture containing water, starchhaving a lowgelatinizing temperature, diastatic enzymes and amino acids whichaccelerate the hydrolysis of starch and heating a continuous stream ofhas been attained said heating from the gelatinizing temperat e of saidstarch to said sterilization point being eflected at a rate of about 1to- 3 degrees ce'ntrigrade increase in temperature per minute.

17. 'Apparatusfor starch conversion and the like comprising-a hopper tohold material come.

enzymes, a water supply tank, mixing trough means,. means for conductingstreams of said material and water from said-hopper and said 6 tankrespectively into said trough. means, means means'in said troughmeansforcontinuously mixing said streams and'conveying the resulting mixturethrough a predetermined path, means said mixture prgressively, whilestirring 'the' posed largely of starch and containing diastatic I forregulating the-size of therespective streams,

for heating the mixture'inatleas't a portion oi said tinuously advancingthe mixture therethrough, means for heating the mixture in saidpreheating section, means forheating the mixtur in said conversionsection and temperature control means associated with said preheatingand conversion sections, respectively, and responsive to thetemperatures of the mixture therein for controlling the respectiveheating means.

19. Apparatus as described in olaim-17, said trough means comprisinginterconnected mixing, preheating and conversion sections, meansassociated with said preheating and conversion sections for introducingsteaminto the mixture garcons 20. A process which comprises continuouslyforming a non-liquid mixture voi cereal starch with water in thepresence .0! diastatic enzymes, a

continuously flowing the mixture through a heating zone, and graduallyheating the mixture in the heating zone through a range or temperaturesat which the enzymes remain active until the starch has becomesubstantially fully gelatinized and converted iiito soluble sugars and aliquid culturing medium has been thus formed.

21. A process which comprises gradually heating starch in admixture withwater and in the thereinto increase progressively the tempera ture ofthe mixture during its passage through presence of enzymes ofAsperyillus oryzae at such temperatures above the cell disruptiontemperature of the starch and for such a time that the starch issubstantially fully disrupted, liquefied and converted before the pointof I I thermal inactivation of said enzymes is attained.

GEORGE A. mars.

